Twisted in wire brush having a molded tip and method of assembly therefor

ABSTRACT

A brush includes a wire core, a round tip formed on a distal end of the wire core, the round tip being unitary with the wire core section and being formed by melting or welding a portion of the wire core at the distal end, and a molded tip attached to the wire core at the distal end via a ball-and-socket connection.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/446,379, now U.S. Pat. No. 10,463,142, filed on Mar. 1, 2017, whichclaims priority to U.S. Provisional Application Ser. No. 62/306,861,filed on Mar. 11, 2016, both of which are hereby in incorporated byreference herein in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to twisted in wire brushes and,more particularly, to a twisted in wire brush having a molded applicatoror cleaning tip, and related method of assembly.

BACKGROUND OF THE INVENTION

Brushes for cleaning the inner surfaces of vessels and/or for applyingmakeup or other personal care product compositions are well known in theart. One type of such brush is the twisted in wire brush, which iscommonly used in a variety of applications including, but not limitedto, hole cleaning, sanding, deburring or lubricating, tube or vesselcleaning, beaker cleaning, pistol, rifle and shotgun cleaning, medicalequipment cleaning, medical and dental procedures, medical applicationsand the application of personal care products including mascara and thelike. Twisted in wire brushes are also known as spiral, tube flue,bottle, pipe, boiler or power brushes, and are generally comprised of aplurality of bristles held and secured by a pair of twisted metal wireswhich form the core of the brush. The bristles are often formed fromsome type of acrylic fiber and extend radially from the core orlongitudinal axis of the brush, generally resulting in a roughlycylindrical appearance. It will be readily appreciated, however, thatthe bristles may be formed from any suitable material including metal,such as stainless steel, brass or bronze, nylon, Teflon, polypropylene,horse or hog hair, depending on the specific use. Moreover, depending onthe specification application, the ends of the brush can also vary. Forexample, a brush may have a rough-cut tip, a rounded tip or a bristledor fan tip, and can have a long end or handle, a short end, or afinished end having various configurations such as a ring or loop.

Other brushes, in addition to, or instead of having bristles held inplace by the twisted wire core, may utilize applicator or cleaning tipscomprised of molded plastic or rubber parts, including plastic or rubberbristles, that are attached to the core section of the brush. Existingmethods of attaching such molded tips to the core section of the brush,however, may often be unreliable. For example, such molded tips may beprone to detachment from the core section of the brush, particularlywhen used in applications such as medical applications and gun cleaningwhere a reasonable force is necessary to effectuate cleaning, deburring,etc. In such applications, the forces generated by the cleaning motioncan sometimes cause detachment of the tip and unraveling of the twistedwire core, which can lead to exposure of often sharp or abrasive ends ofcore wires, making the vessel more prone to scratching and other damage.In addition, detachment of the tip may result in the leaving ofundesirable debris, e.g., bristles or caps, within the vessel that iscleaned or deburred. There is therefore a need to increase thestructural strength of such brushes so as to prevent unraveling inapplications where a reasonable force is needed to effectuate cleaning,deburring, lubricating, etc.

In view of the problems associated with known techniques and methods forforming twisted in wire brushes and, more particularly, for formingbrushes with molded plastic or rubber applicator or cleaning tips, thereis a need for an improved brush that is less prone to tip detachment,and which can be quickly and easily assembled.

SUMMARY OF THE INVENTION

In view of the foregoing, it is an object of the present invention toprovide a brush.

It is another object of the present invention to provide a twisted inwire brush.

It is another object of the present invention to provide a twisted inwire brush having a molded applicator or cleaning tip.

It is another object of the present invention to provide a twisted inwire brush having a molded applicator or cleaning tip that can bequickly and easily integrated with the wire core.

It is another object of the present invention to provide a twisted inwire brush having a molded applicator or cleaning tip that is held insecure engagement with the twisted wire core.

According to an embodiment of the present invention, a brush includes awire core, a round tip formed on a distal end of the wire core, theround tip being unitary with the wire core and being formed by meltingor welding a portion of the wire core at the distal end, and a moldedtip attached to the wire core at the distal end via a ball-and-socketconnection.

According to another embodiment of the present invention, a method offorming a twisted in wire brush having a molded tip includes providing abrush with a wire core, melting a portion of the wire core at an endthereof, by applying an energy source to said end, to form a roundedtip, and securing a molded tip to the end of the wire core through aball-and-socket type connection.

According to yet another embodiment of the present invention, a brushincludes a first brush member including a wire core having a proximalend and a distal end, and a generally spherical tip formed on at leastone of said proximal end and said distal end of said wire core, a secondbrush member including a wire core having a proximal end and a distalend, and a generally spherical tip formed on at least one of saidproximal end and said distal end of said wire core, and a linking memberhaving a body having a first socket formed in a first end of said bodyand a second socket formed in a second end of said body. The generallyspherical tip of said first brush member is received in said firstsocket of said linking member and the generally spherical tip of saidsecond brush member is received in said second socket of said linkingmember such that said first brush member and said second brush memberare linked together in a serial configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be better understood from reading thefollowing description of non-limiting embodiments, with reference to theattached drawings, wherein below:

FIG. 1 is a perspective view of a brush having a molded tip, accordingto an embodiment of the present invention.

FIG. 2 is a side elevational view of the brush of FIG. 1.

FIG. 3 is a cross-sectional view of the brush of FIG. 1, taken alongline A-A of FIG. 2.

FIG. 4 is an exploded view of the brush of FIG. 1.

FIG. 5 is a cross-sectional, exploded view of the brush of FIG. 1, takenalong line B-B of FIG. 4.

FIG. 6 is a cross-sectional view of a brush having dual molded tips,according to an embodiment of the present invention.

FIG. 7 is a perspective view of a twisted in wire brush having analternative tip, according to an embodiment of the invention.

FIG. 8 is a side elevational view of the brush of FIG. 7.

FIG. 9 is a cross-sectional view of the brush of FIG. 7, taken alongline A-A of FIG. 8.

FIG. 10 is another perspective view of the brush of FIG. 7.

FIG. 11 is a perspective view of a twisted in wire brush having analternative tip, according to an embodiment of the invention.

FIG. 12 is a side elevational view of the brush of FIG. 11.

FIG. 13 is a cross-sectional view of the brush of FIG. 11, taken alongline A-A of FIG. 12.

FIG. 14 is a perspective view of a twisted in wire brush having analternative tip, according to an embodiment of the invention.

FIG. 15 is a side elevational view of the brush of FIG. 14.

FIG. 16 is a cross-sectional view of the brush of FIG. 14, taken alongline A-A of FIG. 15.

FIGS. 17-19 are various views of an alternative brush tip, according toan embodiment of the present invention.

FIGS. 20-22 are various views of the brush tip of FIG. 17, shownattached to the rounded tip of a twisted in wire brush.

FIGS. 23-25 are various views of an alternative brush tip, according toan embodiment of the present invention.

FIGS. 26-28 are various views of the brush tip of FIG. 23, shownattached to the rounded tip of a twisted in wire brush.

FIG. 29 is a perspective view of a brush according to another embodimentof the invention.

FIG. 30 is a cross-sectional view of the brush of FIG. 29.

FIG. 31 is a perspective view of a gripping portion of a handle of thebrush of FIG. 29.

FIG. 32 is a perspective view of a coupling member of the handle of thebrush of FIG. 29.

FIG. 33 is a side elevational view of the handle of the brush of FIG.29.

FIG. 34 is a perspective view of a linking element of the brush of FIG.29.

FIG. 35 is a side elevational view of the linking element of FIG. 34.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed to a cleaning or applicator device,more specifically a brush, having a molded plastic or rubber tip, andfurther to a method of manufacturing or assembling the same. The brushis especially adapted to be used for cleaning the interior surfaces ofvessels, such as in medical applications, for example, the cleaning ofcatheters, arthroscopic devices, cameras, etc., and for use in cleaningpistols, rifles and shotguns. In addition, the brush is adapted to beused for applying compositions, such as in personal care applications,for example, the application of mascara.

Referring now to FIGS. 1 and 2, a brush 10 according to an embodiment ofthe present invention is illustrated. As illustrated therein, the brush10 includes a core wire section 12 defining a stem, a plurality offibers or bristles 14 secured by the core wire section 12 and extendingradially therefrom, and a molded tip 16 attached to the core wiresection 12 at a distal end thereof. A handle (not shown) may secured tothe end of the stem opposite the molded tip 16, for allowing a user tograsp and manipulate the brush 10.

In an embodiment, the brush may be fabricated in the customary manner byusing a pliable metallic wire, reversibly folded back upon itself. Aplurality of bristles of predetermined length are placed between the twocoextensive leg portions of the wire. The wire is then twisted to formthe core 12 of helical configuration, which grips the bristles at themidpoint of their length, causing the filaments 14 to be crimped andfolded in half. The outer tips of the bristles 14 define a roughlycylindrical shape of predetermined diameter, or a conical shape. Thebristles 14 may be further trimmed to arrive at various additionalshapes. While this is an exemplary method of forming a twisted in wirebrush, it will be readily appreciated that any fabrication process ormethod for forming twisted in wire brushes known in the art may beemployed, without departing from the scope of the present invention.

For example, it will be readily appreciated that a plurality of wiresmay be used in place of the single wire described above. In such asituation, the plurality of wires may be placed adjacent one another, aplurality of bristles placed between the wires, and the wires twistedtogether to form a core of helical configuration and to anchor thebristles in place. Other methods and configurations of forming wirebrushes and twisted in wire brushes are known in the art and may beincorporated in the current design without departing from the scope ofthe present invention.

In an embodiment, the helical metallic wire core 12 is made up of atleast two coextensive leg portions which are twisted around each otherin a helical configuration and which anchor the bristle block. Themetallic wire core 12 may be comprised of nickel alloys, titaniumalloys, stainless steel alloys, carbon steel alloys, cobalt alloys oraluminum alloys, although other metals or metal alloys may be usedwithout departing from the scope of the present invention. In otherembodiments, the core wire section may include a single length of wire,and the brush need not include bristles held in place by the wire core.

Turning now to FIGS. 3, 4 and 5, the distal end of the core wiresection/stem 12 is formed with an integral, substantially spherical tipor ball 18 that defines a retaining device or anchoring point for themolded tip 16, as discussed hereinafter. The integral ball 18 may beformed on the distal end of the wire core by melting or welding of thedistal end of the core section 12 after twisting of the core 12 toanchor the bristles 14, as disclosed in U.S. Pat. No. 8,850,650, whichis hereby incorporated by reference herein in its entirety. Inparticular, to form the smooth and substantially rounded ball 18 on thebristle end of the core 12, the present invention uses high-energyfusion welding to “melt” the wire core 12 of the brush 10 at the distalend thereof. For example, in the case of a “broken nose” brush, weldingis used to melt the end surfaces of the coextensive leg portions of thepre-constructed core wire section into a consistent, smooth andinseparable rounded tip. In the case of a “continuous end” brush,welding the distal end also melts and eliminates any sharp or unevenedges, and likewise forms a consistent, smooth and inseparable roundedtip. In addition, melting of the core section 12 at the distal end alsoeliminates any contaminant trapping voids that may be present. Oncefused, the coextensive leg portion are unable to be separated from oneanother, and the rounded tip is also inseparable from the core section12. Importantly, welding or melting of the distal end of the core wiresection 12 results in a metallurgical bond between the ball 18 and thecore wire section 12 of the brush 10.

Specific welding technologies such as Laser, Gas Tungsten Arc Welding(GTAW), Plasma Arc Welding and Electron Beam Welding may be used to meltthe bristle end 120 to form the spherical tip 18. In particular, thepreferred parameter range is 0.001 Milliamps to 200 Amps for GasTungsten Arc Welding, 15 Kv-200 Kv for Electron Beam Welding and 1Amp-200 Amps for Plasma Arc Welding, although other parameters may beused. For Laser technology, near ultra violet and/or near infra redlaser sources are preferred, although other wavelengths may be used toachieve the objects of the present invention. While the embodimentsdescribed herein disclose a spherical tip, in certain embodiments, thetip may be generally spherical (i.e., not entirely spherical). The tipmay be spherical to an extent that it can be retained within acorrespondingly shaped (e.g., ball-shaped socket), as discussedhereinafter.

It is a further advantage of the present invention that the sphericaltip 18, once formed, is incapable of being separated from the wire core12, as the core 12 and tip 18 is a unitary welded or melted piece, i.e.,the core wire section 12 and the spherical tip 18 are homogeneous(having been formed from the same piece of material, without theaddition of any other quantity of material). A further advantage of themelted tip 18 formed on the brush 10 of the present invention is thatsuch tip increases the structural strength of the brush itself, whichaids substantially in ensuring that the leg portions of the wire core 12do not become unraveled.

In connection with the above, the integral, spherical tip 18 alsoprovides a mechanism by which the molded tip 16 may be attached andanchored to the distal end of the brush 10. For example, in anembodiment, the molded tip 16 may include a molded core section 20 and amolded bristle section 22 received on the molded core section 20. Asbest illustrated in FIGS. 4 and 5, the molded core section 20 is agenerally cylindrical part having an end 24 having an opening 26 thereinthat extends through the core section to a substantially sphericalcavity 28 opposite the end 24. The spherical cavity 28 defines a socketthat is substantially sized and shaped to closely receive the sphericalball 18 of the core section 12 of the brush 10 therein, as discussed indetail hereinafter. In an embodiment, the molded core section 20 of themolded tip 16 is formed from plastic or other polymer.

As also shown in FIGS. 4 and 5, the molded bristle section 22 of themolded tip 16 defines a generally hollow body having a plurality ofbristles 30 extending outwardly therefrom. The interior of the hollowbody is sized and shaped so as to closely receive the molded coresection 20 therein. In the preferred embodiment, the molded bristlesection 22 of the molded tip 16 is formed from rubber.

In an embodiment, the molded core section 20 may be secured to themolded bristle section 22 by any means known in the art, such asutilizing adhesives and the like. In other embodiments, the moldedbristle section 22 and the molded core section 20 may be formed as asingle, integral part. The molded bristle section 22 and molded coresection 20 may be formed utilizing any molding process known in the artsuch as, for example, injection molding, rotational molding,thermoforming, etc.

In an embodiment, after the molded tip 16 is formed by joining themolded bristle section 22 with the molded core section 20, the tip 16may be secured to the wire core 12 of the brush by sliding the moldedtip 16 over the distal end of the core 12 until the spherical ball 18contacts the shoulder 32 between the socket 28 and the cylindricalcavity that extends through the core section 20. Axial pressure is thenutilized to force the spherical ball 18 into seated position within thesocket 28, forming a ball-and-socket type joint or connection. In thisposition, the geometry of the ball 18 and socket 28 prevents decouplingof the molded tip 16 from the core section 12 of the brush 10, andsecurely holds the molded tip 16 on the distal end of the core section12. As shown in FIGS. 3 and 5, the socket 28 may be formed at a distalend of the molded tip 16 such that at least a portion of the wire coresection 12 is received within the passageway in the molded tip 16. Thisconfiguration provides a more robust connection between the molded tip16 and wire core 12, minimizing lateral or pivoting movement of tip 16relative to the wire core 12. In certain embodiments, it is contemplatedthat various molded tips corresponding to various functions may beselectively attached and detached from the wire core 12 to provide alevel of customization and functionality heretofore not seen in the art.

Importantly, this ball-and-socket type connection provides for a costeffective and efficient means of assembling a molded plastic or rubberbristle block onto the distal end of a twisted in wire brush. Inaddition, the ball-and-socket attachment mechanism provides for a secureconnection that is less prone to decoupling than existing methods anddevices. In contrast to existing devices, in the rare event that themolded tip does become decoupled from the core wire section, the smoothsurface of the integral tip 18 of the core wire section prevents thebrush from scratching, scarring or damaging sensitive surfaces,particularly before such decoupling is detected by a user.

Moreover, in yet another embodiment of the present invention, a methodis provided for forming a protective tip on a cleaning apparatus. Suchmethod involves manufacturing a brush, in particular a twisted in wirebrush, as hereinbefore described. The method further comprises the stepsof positioning the bristle end of the cleaning apparatus or brushadjacent to an electrode or laser, shielding the bristle block, and“melting” a pre-constructed core wire section of the brush into aconsistent, smooth, unitary and inseparable rounded tip. This roundedtip, once formed, is unable to be separated from the wire core, thusreducing the risk of cleaning surface damage, as hereinbefore described.In addition, the method further includes attaching a molded tip having aplurality of bristles to the rounded tip of the brush by pushing themolded tip onto the rounded tip of the core until the rounded tip of thecore is received in a socket within the molded tip.

While the embodiments described above contemplate the attachment of amolded rubber bristle block to the distal end of a twisted in wirebrush, the present invention is not so limited in this regard. Inparticular, the brush having the ball-and-socket attachment mechanism ofthe present invention may be utilized in a variety of applications, tosecure a variety of attachments to the distal end of a wire core sectionof a brush having an integral, rounded tip. For example, the presentinvention contemplates use in cosmetic applications such as forattaching overmold parts to twisted in wire brushes for nail enamel andmascara application, in medical applications including endoscopy,cytology, general cleaning, stylets, etc., gun care applicationsincluding swabs and brushes, and general cleaning applications. Asindicated above, the integral ball 18 of the core section 12 of the wirebrush 10 may be utilized to attach various attachments to the distal endof the brush 10, and is not limited to attaching bristle sections or thelike. For example, in an embodiment, the ball 18 may be utilized toattach a dome or disc shaped diaphragm or squeegee to a wire coresection, to be utilized for cleaning interior surfaces or evenlyapplying a composition to such interior surfaces.

Referring to FIG. 6, it is also contemplated that the proximal end ofthe core wire section opposite the bristle block (e.g., the handle end)may also be melted to form a second rounded, unitary tip 50 to which asecond molded tip 52 or other accessory may be attached via a similarball-and-socket type connection. The second molded tip, for example, mayhave a different bristle configuration than the molded tip on the distalend of the brush (e.g., shorter or denser bristles), or may be adifferent accessory altogether (e.g., a diaphragm 52 or squeegee). Thebrush of the present invention may therefore provide for dual functionsor uses, obviating the need to use multiple, distinct brushes to performdiffering functions.

FIGS. 7-10 illustrate an alternative molded brush tip 100 attached tothe spherical or ball-shaped tip 18 of a twisted in wire brush 200. Thetwisted in wire brush 200, is formed in the manner, and has the sameconfiguration, as the twisted in wire brush discussed above. As showntherein, the brush tip 100 is a single molded piece having a coresection 102 including a ball shaped socket 104, and a plurality ofbristles 106 connected to, and extending from, the core section 102. Incontrast to the tip 16 described above, the socket 102 of the brush tip100 is located at a proximal end of the tip 100 (i.e., rather than at adistal end). The tip 18 of the brush 200 is received in the socket 104of the brush tip 200. As illustrated in FIGS. 7-10, the connection pointbetween the brush tip 100 and the brush 200 is at the midpoint of theassembled brush. As shown in FIG. 10, this permits the brush tip 100 topivot relative to the brush 200 (i.e., the articulated ball-and-socketjoint permits pivoting about such joint).

FIGS. 11-13 illustrate an alternative molded brush tip 300 attached tothe spherical or ball-shaped tip 18 of a twisted in wire brush 200. Thetwisted in wire brush 200, is formed in the manner, and has the sameconfiguration, as the twisted in wire brush discussed above. As showntherein, the brush tip 300 is a single molded piece having a coresection 302 including a ball shaped socket 304 at a distal end thereof,and a plurality of bristles 306 connected to, and extending from, thecore section 302. Like tip 16 described above, the socket 302 of thebrush tip 300 is located at the distal end of the tip 300. As showntherein, the tip 18 of the brush 200 is received in the socket 304 ofthe brush tip 300 such that the assembled brush includes a bristlesection 14 (with bristles held in place by the twisted core section 12of the brush), and a bristle section 302 (with bristles formed in themolded tip 300).

FIGS. 14-16 illustrate another molded brush tip 400 attached to thespherical or ball-shaped tip 18 of a twisted in wire brush 200. Thetwisted in wire brush 200, is formed in the manner, and has the sameconfiguration, as the twisted in wire brush discussed above. As showntherein, the brush tip 400 is a single molded piece having a coresection 402 defining a ball shaped socket 404, and a plurality ofbristles 406 connected to, and extending from, the core section 402. Thetip 18 of the brush 200 is received in the socket 404 of the brush tip400 such that the assembled brush includes a bristle section 14 (withbristles held in place by the twisted core section 12 of the brush), anda bristle section 402 (with bristles formed in the molded tip 400).

Turning now to FIGS. 17-19, a molded brush tip 500 according to anotherembodiment of the present invention is illustrated. As shown therein,the brush tip 500 is a single molded piece having a core section 502including a ball shaped socket 504 at a distal end thereof, and aplurality of bristles 506 connected to, and extending from, the coresection 502. Like tip 16 described above, the socket 502 of the brushtip 500 is located at the distal end of the tip 500.

FIGS. 20-22 illustrate the brush tip 500 attached to the spherical orball-shaped tip 18 of a twisted in wire brush 200. The twisted in wirebrush 200, is formed in the manner, and has the same configuration, asthe twisted in wire brush discussed above. As shown therein, the tip 18of the brush 200 is received in the socket 504 of the brush tip 500 suchthat the assembled brush includes a bristle section 14 (with bristlesheld in place by the twisted core section 12 of the brush), and abristle section 502 (with bristles formed in the core section 502 of themolded tip 500). In particular, as shown therein, the rows of bristles506 of the tip 500 are received intermediate the bristles 14 of thetwisted wire core 12 of the brush 200 to form a nesting or intermeshedarrangement of bristles.

Turning finally to FIGS. 23-25, a molded brush tip 600 according to yetanother embodiment of the present invention is illustrated. As showntherein, the brush tip 600 is a single molded piece having a coresection 602 including a ball shaped socket 604 at a distal end thereof,and a plurality of bristles 606 connected to, and extending from, thecore section 502. Like tip 16 described above, the socket 502 of thebrush tip 600 is located at the distal end of the tip 600.

FIGS. 26-28 illustrate the brush tip 600 attached to the spherical orball-shaped tip 18 of a twisted in wire brush 200. The twisted in wirebrush 200, is formed in the manner, and has the same configuration, asthe twisted in wire brush discussed above. As shown therein, the tip 18of the brush 200 is received in the socket 604 of the brush tip 600 suchthat the assembled brush includes a bristle section 14 (with bristlesheld in place by the twisted core section 12 of the brush), and abristle section 602 (with bristles formed in the core section 602 of themolded tip 600). In particular, as shown therein, the row of bristles606 of the tip 600 are received intermediate the bristles 14 of thetwisted wire core 12 of the brush 200 to form a nesting arrangement ofbristles. As will be readily appreciated, utilizing a tip 600 havingthis configuration of bristles 606 as an attachment to a twisted in wirebrush 200 having an integral, rounded tip 18 allows the array ofbristles in one part of the assembled brush to be denser than thebristles in other parts of the brush.

Turning finally to FIGS. 29-35, the present invention is not so limitedas merely securing molded tips to the end of a twisted in wire brush. Inparticular, it is envisioned that the spherical tip may also be utilizedas an anchoring point to link various accessories and devices to oneanother in a serial configuration. For example, as illustrated in FIGS.29-35, the system and method of the present invention can be utilized tolink multiple bristle sections to one another to form a device 700 forcleaning a longitudinal bore, such as the barrel of a firearm.

As shown in FIGS. 29 and 30, for example, the device 700 may include ahandle 710 and a plurality of brushes (such as twisted in wire brushes712, 714, 716) coupled to the handle 710 and linked end-to-end by aplurality of coupling or linking members 718. In an embodiment, thedevice 710 may also include a spacing element 720 (depicted in FIGS. 28and 29 as a twisted wire core portion having spherical tips 722, 724 onthe opposite ends thereof, formed in accordance with the processdescribed hereinbefore) intermediate the brush 712 and the handle 710for spacing the brushes 712, 714, 716 distal from the handle 710.

With reference to FIGS. 31-33, the handle 710 may be a two part pieceincluding a gripping member 726 having opposed arms 728, 730 and athreaded aperture configured to threadedly receive a correspondinglythreaded stud or shaft 734 of a coupling member 732. Alternatively, thegripping member 726 and coupling member may be formed as a unitarycomponent. As best shown in FIG. 32, the coupling member 732 includes asocket 736 located in an end of the coupling member 732 opposite thestud 734, and which is configured to receive therein the spherical tipor ball 722 on the proximal end of the spacing element 722 (or,alternatively, the spherical tip of a brush).

As illustrated in FIGS. 34 and 35, the linking members 718 each includea generally cylindrical body 738 having a pair of opposed recesses orball-shaped sockets 740, 742 formed in the opposing ends thereof. Thesockets 740, 742 are configured to receive therein the spherical,ball-shaped tip of either the spacing element 720, one of the brushes712, 714, 716, or another accessory such as a squeegee or diaphragm. Inan embodiment, the linking members 718, coupling member 732 and grippingmember 726 may be formed from plastic or other polymer, although othermaterials known in the art may also be utilized without departing fromthe broader aspects of the invention.

Referring once again to FIGS. 29 and 30, the spacing element 720,brushes 712, 714, 716 and other accessories can each be manufactured toinclude a spherical tip 750 on one or both ends thereof in the mannerdiscussed above (i.e., by welding or melting the end(s) of the wire coresection of each such accessory or brush). The spacing element 720,brushes 712, 714, 716 and other accessories may then be linked serially,end-to-end by mating the spherical tips within the sockets of thelinking members 718 to form a chain. The device 700 may then be insertedinto a longitudinal bore, such as a gun barrel, and pulled through thebore for surface preparation or cleaning. In an embodiment, the brushes712, 714, 716 may be more or fewer than three brushes, and can havedifferent specifications from one another (e.g., different bristledensities, stiffness, thickness, bristle block diameters etc.) forproviding different surface treatments. Importantly, this configurationallows any such device to be easily customized or adapted to perform aspecific function by adding or subtracting brushes or accessories.

While the embodiments described above disclose and show the use of amechanical fit, such as a snap fit or friction fit, to secure thespherical tip to a molded tip, linking member or coupling member, otherredundant securing means may also be utilized without departing from thebroader aspects of the present invention. For example, in certainembodiments, heat may be applied (such as to the molded tip or linkingmembers) to slightly melt or heat-shrink the molded tip or linkingmembers so that the internal passageway and/or socket therein moreclosely conforms to the ball-shaped end of the wire core. In addition,heat may be selectively applied to the molded tip to form prongs orprojections that extend towards the core wire section to inhibit removalof the molded tip from the core wire section.

Although this invention has been shown and described with respect to thedetailed embodiments thereof, it will be understood by those of skill inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of theinvention. In addition, modifications may be made to adapt a particularsituation or material to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodimentsdisclosed in the above detailed description, but that the invention willinclude all embodiments falling within the scope of this disclosure.

What is claimed is:
 1. A method of forming a twisted-in-wire brush,comprising the steps of: providing a brush with a wire core and aplurality of bristles defining a bristle block extending radially fromsaid wire core and anchored in said wire core; melting a portion of saidwire core at a distal end of said wire core, by applying an energysource to said distal end, to form a generally spherical tip; andmounting a molded tip to said spherical tip.
 2. The method according toclaim 1, wherein: said molded tip includes a plurality of bristles and asocket formed in said molded tip; wherein said step of mounting saidmolded tip to said spherical tip includes axially moving at least one ofsaid molded tip and said wire core relative to the other of said moldedtip and said wire core until said spherical tip is received within saidsocket of said molded tip.
 3. The method according to claim 2, furthercomprising the step of: shielding said bristle block from said energysource prior to said step of melting to prevent damage to said bristleblock.
 4. The method according to claim 2, wherein: said wire coreincludes a plurality of twisted leg portions formed from metal; and saidmolded tip is formed from at least one of plastic and rubber.
 5. Themethod according to claim 4, wherein: said socket is located at aproximal end of said molded tip.
 6. The method according to claim 4,wherein: said socket is located at a distal end of said molded tip. 7.The method according to claim 4, wherein: said step of melting a portionof said wire core to form said spherical tip is achieved by at least oneof laser beam welding, gas tungsten arc welding, plasma arc welding andelectron beam welding.
 8. The method according to claim 1, furthercomprising the steps of: melting a portion of said wire core at aproximal end of said wire core, by applying the energy source to saidproximal end, to form a second generally spherical tip; and mounting asecond molded tip to said second spherical tip.
 9. The method accordingto claim 1, wherein: the molded tip defines a linking member having afirst socket and a second socket opposite the first socket; wherein thefirst socket is configured to receive the spherical tip of the brush;and wherein the second socket is configured to receive a secondspherical tip formed on an end of a second brush such that the brush andthe second brush are linked end-to-end.